Clutch Hydraulic System: Service and Repair

STANDARD PROCEDURE-BLEEDING CLUTCH HYDRAULIC CIRCUIT

NOTE: It is necessary to bleed the clutch hydraulic release system if the system has lost an excessive amount of fluid and has allowed air into the circuit. Air in the system typically results in a spongy pedal feel, and/or improper clutch release. If air cannot be removed from the system using this procedure, it is necessary to replace BOTH the clutch master cylinder and slave cylinder assemblies.


1.6/2.0/2.4L MODELS (Except Turbo)
From driver's seat, actuate clutch pedal 60-100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:

1. Verify fluid level in clutch master cylinder reservoir. Top off with DOT 3 brake fluid as necessary.
2. Raise vehicle on hoist.










3. Remove clutch slave cylinder assembly from the transaxle case (Fig. 3) (Fig. 4), but do not disconnect from the system. Allow the slave cylinder hang, making it the lowest part of the system.

CAUTION: While slave cylinder is detached from the transaxle, DO NOT actuate the clutch master cylinder. Damage to the slave cylinder will result.

4. Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten (10) times, forcing trapped air upwards and out of the system.
5. Re-install slave cylinder into position.
1.6L equipped models: Torque slave cylinder to case bolt to 12 Nm (105 inch lbs.)
2.0/2.4L equipped models: Torque slave cylinder to case bolt to 19 Nm (168 inch lbs.)
6. Lower vehicle.
7. Check and adjust clutch master cylinder fluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, air is still trapped within the system. Repeat Step 3 - Step 7 until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies.
8. Raise vehicle.
9. Lower vehicle.
10. Top off clutch master cylinder fluid level with DOT 3 brake fluid as necessary.